Pressurized multiconductor bulkhead connector assembly



March 16, 1954 BONDON 2,672,500

PRESSURIZED MULTICONDUCTOR BULKHEAD CONNECTOR ASSEMBLY Filed Sept. 19, 1951 FIG.- I. ,7

FIG. 2 I FIG. 3.

I N VEN TOR LEWIS A. aouoou ATTORNEYS Patented Mar. 16 1954 PRESSURIZED MULTIGONDUCTOR BULK- HEAD CONNECTOR ASSEMBLY Lewis A. Bondon, Arlington, N. J.

Application September 19, 1951, Serial No 247,330

6 Claims. (Cl. 174153) This invention relates to connecting devices for insulated conductors and has more particular reference to a pressurized multi-conductor bulkhead connector assembly.

One object of the present invention is to provide a new and unique improved pressurized multi-conductor bulkhead connector assembly including a pressurized gland through which the conductors are mounted and sealed, enabling the assembly to be readily installed through the bulkhead of a pressurized compartment, making a gas or fluid-tight seal between the bulkhead member and gland. v

A further object of the invention is to provide a pressurized multi-conductor bulkhead connector assembly, as characterized above, wherein means are provided within the gland to prevent any leakage of gas or moisture therethrough.

A further object of the invention is to provide a pressurized multi-conductor bulkhead connector assembly, as characterized above, wherein a portion of the insulation is removed from each of the conductors within the gland and the inside of the assembly is filled with a sealing compound to hermetically seal the gland against entrance of gas or moisture.

Another object of the invention is to provide a pressurized gland connector assembly for use in connecting ends of multiple conductors together where they pass through the bulkhead of a pressurized compartment and provide a fluidtight joint between the bulkhead and gland and prevent leakage of gas or moisture through the gland.

A further object of the invention is to provide a pressurized gland connector assembly, as characterized above, which is simple in construction, quickly and easily installed on the job by a workman, and efiicient in accomplishing its function after installation.

Other objects and advantages of the invention will appear in the following specification when considered in connection with the accompanying drawings, wherein:

Fig. 1 is a side elevational view of a pressurized multi-conductor bulkhead connector assembly constructed in accordance with the present invention;

Fig. 2 is a longitudinal sectional view of the assembly shown in Fig. 1;

s Fig. 3 is a longitudinal sectional view similar to that shown in Fig. 2, but with the conductors and sealing compound omitted; and

. Fig. 4 is an end elevational view of the assembly shown in Fig. 3. I

--...W.. zone or, more insulated conductorsare passed through a gland or bushing extending through a bulkhead or wall enclosing a pressurized compartment, it is extremely difficult to prevent air from leaking through the gland or to maintain stable electrical values. Particu larly is this so in an insulated stranded wire conductor where the air may pass along the stranded conductor beneath the insulating covering, or even a single wire conductor when the insulating covering is made of woven or braided material, where the air may pass through the openings in the covering.

The present invention provides a pressurized multi-conductor bulkhead connector assembly which overcomes these difiiculties and prevents any leakage of air or moisture therethrough and providing stable insulation resistance values.

In general, the invention comprises a pressurized multi-conductor bulkhead connector assembly including a pressurized gland or bushing having external flanges or the like 'by means of which a fluid-tight joint is made between the bushing and the bulkhead; a pair of insulating 7 terminal blocks mounted in longitudinal alignment within the bushing and having a plurality of longitudinally extending and aligned bores therein; an insulated conductor extending into ach of the bores in said terminal blocks and having a portion of its end free of insulation; means for electrically connecting and sealing the opposed ends of the conductor in each aligned pair of bores; and a sealing compound filling the air spaces in said bushing for hermetically sealing the assembly against leakage of air or moisture therethrough, thus maintaining stable electrical conditions through this assembly.

The invention contemplates that completed assemblies, including the conductors, be manufactured to specification and shipped ready to be installed merely by passing the conductors through the designed opening in the bulkhead and securing the bushing therein to make a fluidtight joint between the bulkhead and the bushing.

The invention further contemplates that integrally packaged bulkhead assemblies, including the bushing, the terminal blocks and sleeve connectors, be supplied ready for installation by the worker on the job by securing the opposed ends of corresponding conductors within the assembly and then forcing a sealing compound therein to hermetically seal the'assembly. Such assemblies find many uses in the aircraft building industr as for example, in the installation of low tension electric control systems. --.;tReferrlng nowto the drawings, there is shown lines I thereof.

a preferred embodiment of a pressurized multiconductor bulkhead connector assembly constructed in accordance with the present invention. In Figs. 1 and 2, the connector assembly is shown complete and mounted through a bulkhead or wall. In Figs. 3 and 4, the assembly is shown with the conductors and sealing compound omitted. The completed connector assembly comprises" an outer sleeve-like shell or bulkhead bushing ll], shown in Figs. 1 and 2 as extending through an opening in a bulkhead B; a pair of insulator terminal blocks. H- and l2, each having a plurality of circumferentially spaced longitudinal aligned bores I3 extending therethrough; a plurality of sleeve connectors H; a plurality of corresponding insulated wire conductor l5 extending through aligned bores in said bushing and with their ends makin electrical contact inside of a sleeve; an O-ring gasket l6; and a lock nut li threadedly'mounted on one end of the bulkheadbushing for securing the bushing onthe bulkhead;

The bulkhead bushing It! may be made of any suitable material, preferably; and as shown, it is made of cadmiurn plated brass. l'fhe bushing I0 is provided with an integrally formed outwardly extending flange I8 having an: annular recess l9 formedtherein for the reception of., the

O-rin packing or gasket l6. The gasket I'6 maybe made of any suitable material; but, preferably, and as shown, is'made'of'neoprene; one end of the bulkhead'bushing is threaded, as indicated at 20, for the reception of'the lock nut IT.

The insulator terminal block H and I! may be made of any'suitablematerial; but, preferably, and as shown, they are-made ofhard rubber: or Textolite. The insulators H and I) are mounted withinthe bulkhead bushing in longitudinal alignment and each is shown as having a cylindrical shapewith aconical shaped: recess ll formed inits inner end and with its outer end substantially fiat. CircumferentialIy spaced cylindrical bores I3,- four'such being shown, extendthroughthe bushing and are radially spaced an equal distance from the longitudinal center Each of the bores-13 is identical in construction and each is 1 counterbored to pmvide an inner portion 22 having a diameter slightly greater than the diameter of the m maindin'g outer portion, so that" the juncture point of the-twoportions forms aradlalshouldbr 24'.

Th insulator terminal block H is provided with a centrallypositioned longitudinalbore fi communicatingwith the space between the two insulator terminal blocks H and f2" (-see F lg. 2).

The sleeve connectors I4 are of identlcalconstruction and may be madeoi' any suitable material, preferably, and as shown, they are-made of brass; Each sleeve comprises a hollow'cyllndricalopen-ended member having a centrallypositioned radial opening 26 throughitsside -wall, for a purpose hereinafter to be described. The external diameter of the sleeves" It is slightly smaller thanthe diameter of the inner endpor tions 22 and is slightly largerthan' the diameter of the outer end portions 23 of thebores 1! formed in the insulator terminal blocks. Each sleeve is mounted in a pair of corresponding aligned bores l3 in 'the terminwl bloks I l and" with it's. ends abutting-the Shoulders M mspect'ivebores;

The vcorresponding: opposed'ienda 0'! eldl'f'or the insulated i conductors: *l 61 :ammuuntedim tha amu- 4 minal blocks H and I2. The end portions 21 of the insulated conductors l5 which extend into the sleeve connectors in abutting or overlapping relation are bared of insulation and are soldered together by melted solder being poured in the radial openings 26 in the sleeve connectors (see Fig. 2)

The two insulator terminal; blocks Hi and I2 abut a centrally positioned annular-shoulder 28 formed integral with the bushing ill. The peripheral outer end edges of the bushing III are rolled or-crimped; as indicated at 29, to hold the two terminal .blocks in place.

The space between the terminal blocks II and I2 and allof'the air spaces in the bores l3 and the, sleeve connectors M are filled with a gasoline and oil resistant sealing compound 30, preferably' a neoprene base potting compound or a polyvinyl chloride potting compound, to effectively hermetically sealthe interior of thexbushing againstgas andfluids, including the-passage of gases along the conductors.

The lock nut I1 islmade of brass; and is screwed on the threaded endlof the bulkhead bushing: l0 after it has been mounted in the openingin'zthe bulkhead in which the connectoriszto bemounted; as shown in Figs. 1 and 2; thus effectively making the joint between. the bulkhead. and the bushing: fluid-tight.

When the pressurized: gland assembly,- as shown: in Figs. 3 and. i, isshipped' as a: unit;for use by a workman in making a pressurizedmultieconductor connector assembly on the, job, the installation may be made as follows: th inner end of each of the individual: conductors which are to be connected have their insulation re--.- moved to expose thebare conductor fora distance equal to one-half the length of a sleeve c0nnect0r,' then, the left hand: conductors, are individually threaded through the bores in the left hand insulator terminal: block II, as viewed inaFig. 3; and the right hand conductors are individually threaded through the pores in the right hand insulator terminal block I231 next; the terminal blocks arepushedbaok on=the co n ductors and! the bulkhead bushing: is: passed? over all of the left hand conductors and pushedbw! thereon: next, the bareends: of the correspondll'lg conductors are inserted mwthe opposite cnds of sleeve connectors I4 until they contact or overlapeeach other; then, meltedsoider' iii-poured into? the radial -openings: 28 in the sleevehrnectors to solder the bare ends of the conductors together; next, thebulkheadbushing' is pushed forward on the left hand conductors until item closes-the -sleeve connectomz then, the left hand and right hand insulator terminal blocks ane pushed inwardly on the conductors aaid lnto the bulkhead bushing until they come up against the inwardly extending flanges no! thebullr head bushing; this: movement results imeach-o! sleeve connectors being seated iii-correspond ing bores in the insulator t'erminatblboh; with the ends of "the sleevesabutting the shoulders 24 in theflboresl 3''; next; the-outer peripheral-ends of the bulkhead bushingare criinped into the outer surface of the two insulator terminal-blocks to secure the assembly: and; finally, a suitable sealing compound i'sforced, under promote, through the cent'ral bore zb in the insulator terminal block' l l until it' fills all the voids mithe assembly and exudesout or theouter ends: of the. bores I 3 in each ternnnal block around the insulated conductor therein: Mter the "sealing 1- will m sssembly is complete and i pressure-tight against gases and liquids; then, the bulkhead bushing is secured in the designated opening in the bulkhead by the lock nut l? to form a fluid-tight joint between the bulkhead and the bushing.

While the pressurized multi-conductor bulkhead connector assembly illustrated and described has been shown as designed to connect or carry only four insulated conductors, obviously, any reasonable number of such conductors could be included in the assembly.

While the bulkhead bushing has been shown as being adapted to be secured in an opening in a bulkhead by a l bel: nut, obviously, it could be secured to the bulkhead by bolts and nuts, or by soldering.

Obviously, the invention is not restricted to the embodiment thereof herein shown and described.

Having thus described the invention, what is claimed is:

1. A pressurized multi-conductor bulkhead connector assembly comprising a bulkhead bushing adapted to extend through an opening in a bulkhead and provided with means includ ng an outwardly extending flange to permit it to be secured therein, a pair of lcngitudinally aligned insulator terminal blocks mounted in said bulkhead bushing, said insulator blocks having a plurality of horizontally extending circumferential- 1y spaced and aligned bores extending therethrough, and an open-ended sleeve mounted be tween each aligned pair of bores in said insulator blocks with its ends extending part way into said pair of bores, a pair of longitudinally aligned conductors mounted in each of said sleeves with their inner adjacent ends in electrical contact with each other and with their outer ends extending through the respective bores in said insulating blocks in which the sleeve is mounted, and a gasoline and oil resistant sealing cement filling all air spaces within said assembly to the exclusion or air therefrom.

2. A pressurized multi-conductor bulkhead connector assembly, as set forth in claim 1,

insulation; wherein each of said sleeves is provided with a centrally positioned radial opening for the insertion of the solder required to solder the ends of the conductors therein and to permit the sealing cement to be forced therein; and wherein one of said insulator blocks is provided with an opening extending therethrough to permit said sealing cement to be forced into the interior of said connector assembly.

3. A pressurized multi-conductor bulkhead connector assembly, as set forth in claim 2, wherein said insulator blocks are slidably mounted in said bulkhead bushin and wherein said bulkhead bushing is provided with an inwardly projecting annular flange intermediate its ends which acts as a stop for said insulator blocks 6 and wherein the outer peripheral edges of said bulkhead bushing are crimped into the outer surfaces of said insulator blocks to hold said assembly together.

4. A pressurized multi-conductor bulkhead connector assembly, as set forth in claim 3, wherein the inner adjacent end portions of each of said aligned pairs of bores are counterbored to form circular shoulders which act as abutments for the ends of the sleeves extending into the respective bores.

5. In a bulkhead bushing assembly for connecting the ends of a plurality of insulated conductors and making a fluid-tight joint between the bushing assembly and a bulkhead or the like and hermetically sealing the interior of the bushing assembly, the combination comprising a bulkhead bushing adapted to extend through an opening in a bulkhead and provided with means including an outwardly extending flange to permit it to be secured therein; a pair of insulator terminal blocks each having a plurality of longitudinal, circumferential'y spaced bores extending therethrough, said terminal blocks being slidably mounted in said bushing with the bores therein in longitudinal alignment, one of said insulator blocks being provided with an opening extending therethrough to permit a sealing cement to be forced into the interior of the assembly to exclude all air therefrom; a plurality of open-ended sleeve connectors, each mounted between an aligned pair of bores in said insulator blocks with its ends e tending part way into the respective bores of the pair, said sleeve conf nectors being adapted to receive the bare free ends of individual insulated conductor when said conductors are inserted into said bores and said sleeves having centrally positioned radial openings therein through which melted solder may be poured to solder the free bare ends 01. said conductors together.

6. A bulkhead bushing assembly, as set forth in claim 5, wherein said bulkhead bushing is provided with an inwardly projecting annular flange intermediate its ends which acts as a stop for said insulator blocks and wherein the inner adjacent end portions of each of said aligned pairs of bores are counterbored to form circular shoulders which act as abutments for the ends of the sleeves extending into the respective bores.

LEWIS A. BONDON.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 2,265,341 Borchert Dec. 9, 1941 2,509,341 Goldsmith May 30, 1950 FOREIGN PATENTS Number Country Date 262,532 Great Britain Dec. 16, 1926 567,618 Great Britain Feb. 23, 1945 572,079 Germany Mar. 10, 1933 

